Electric switch



Oct. 25, 1938. A. c. GAYNOR ELECTRIC SWITCH Filed June 12, 1936 r 3 3 3 a E 3 13 MW 0 3 3 J? um m M A A3 u V 3 .333 3,//

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Patented Oct. 25, v 1938 UNITED STATES PATENT UFF'ICE 2,134,633 4 ELECTRIC swr'ron Arthur C. Gaynor, Stratford, Conn. Application Jamie, 1936, Serial No. 84,780 16 Claims. (crate-67) This invention relates to electric snap switches, and more particularly aims to provide improvements in the construction of snap switches of the toggle type.

5 It is a general object of this invention to provide an improved electric toggle switch, the construction of which is outstandingly simple, so that manufacturing costs are low, while yet maintaining an efliciency of operation of the m switch which is extremely high.

In the accomplishment of this object the present invention contemplates, in such a switch, an improved toggle construction, improved contact elements, and also an improved switch mecha- M nism supporting structure.

- In a certain type of toggle switch adapted for plate mounting the means for mounting the switch on the plate includes an externally threaded sleeve or barrel which carries clincher nuts to 20 grip the plate, the toggle actuating leverof the switch being carried by the barrel so as to protrude from the supporting plate for easy access and manipulation. In these switches it has been the custom, prior to this invention, to carry piv- 25 otally the manually actuated switch lever on a I pin which passes through oppositely disposed apertures in the barrel, said pin being supported or anchored in the barrel. This has necessitated the provision of a barrel having substantially a some; well, has required additional machining operations onthe barrel, and further has been undesirable in that there existed the possibility of injury to the threads of the barrel.

These disadvantages have been overcome by at the present invention, which. provides an improved supporting structure for the manually actuated lever of the switch, which structure does away with the necessity for a thick walled barrel, since the pivot pin for the actuatable lever is not Ml supported in the barrel.

According to thepresent improved structure the switch is provided with a cover plate which 45 attached thereto a relatively thin walled mounting barrel which houses over the outwardly extending lugs 01 the plate, and serves now to position the pin against endwise movement, and which barrel also acts as a guide for the switch By this construction there is avoided the extra machining operation .which would otherwise be required in anchoring the pivot pin in the mounting barrel, as well as avoided the possibility of marring o! the threads of the barrel, 66 which was 7 present with the prior less desirable supporting means. Thebarrel thus now func tions to mount the switch, to limit endwise movement of the pin, and to cover the supporting lugs or the plate. a

The present invention additionally provides 5 a simple and effective means for attaching the mounting barrel to the cover plate of the switch such that the two are firmly held together, and such that there is positively prevented any possi bility of relative turning between these parts. 10-

In accordance with the expressed general object there is also provided asimplified toggle mechanism for actuating the contact bridging members of the switch in response to movement of the switch handle or lever, and additionally provided improved electrical contact means'coacting with the toggle-actuated bridging members of the switch.

By the provision of the improved electrical contact means in the switch, it has been possible to simplify and make more compact the housing or casing of the switch, resulting in a desirable smallness of size and further economy of manufacture, yet without sacrificing satisfactory operation and high emciency ofv the article.

Other features and advantages will hereinafter appear.

In the accompanying drawing:

Figure 1 is a side elevation of an embodiment of the improved switch of this invention.

Fig. 2 is a top view of the switch of Fig. l, with part of the insulating shield, mounting barrel, and plate cutaway to reveal the improved contact bar with its lug.

Fig. 3 is a broken longitudinal vertical section taken on the line 3-3 of Fig. 2.

Fig. 4 is a transverse vertical section through the switch.

Fig. 5 is a top view of the insulating casing of the switch, with one of the improved contact 40 bars in place.

Fig. 6 is a perspective view of one of the improved contact bars of this invention.

Fig. 7 is a top plan view of the cover plate of the switch.

Fig. 8 is a side view of the plate of Fig. '7.

Fig. 9 is an elevation of the mounting shell or barrel of the switch before being attached to the cover plate.

Fig. 10 is atop view of the barrel oi Fig. 11 is a plan view of the tcggl ate.

Fig. 12 is a side elevati a modified form of toggle mechanis Fig. 13 is an end elevation of the modified toggle mechanism of Fig. 11. g V

in Figs. 1, 2, 3, and 4, includes an insulating housing or casing 20, an insulating shield 2|, a

cover plate 22 and a mounting barrel or shell 23 through which extends an actuating lever 24 carrying a spherical hand-knob or ball 25. As usual, the mounting barrel 23 is provided with clamping nuts 23a to engage the margins of an aperture in a supporting plate or structure through which the barrel extends. The casing 20, see Figs. 3, 4, and 5, is preferably molded from suitable insulating material such as Bakelite, and has a box-like shape having a bottom 26, side walls 21, and end walls 28, the top of the casing being open. The cover plate'22, Figs. 7 and 8, closes over the top of the casing 20, there being interposed between the plate 22 and the casing the rectangular insulating shield 2 i.

According to the present invention, the cover plate 22 is adapted to act as a mounting for theactuating lever 24 of the switch. The plate 22, see Figs. '7 and 8, is stamped from a circular disk of metal, having flat or straight edges 29, a central circular raised portion 36, partially circular apertures 3| in said raised portion, and lugs or ears 32 having apertures 33, said lugs being later bent outwardly to extend, as shown by the broken lines in Fig. 8, so as to form trunnions for the support of the switch lever. The lugs 32 carry a pin 34, Fig. 4, which passes through the apertures 33 in said lugs, and which pin pivotally supports the lever 24 of the switch.

It will be noted that the lever 24 is thus not mounted in the barrel 23, but is mounted for pivotal movement on the cover plate 22 about the pin 34, and said mounting does not require therefore that the barrel 23 have a heavy wall as with prior switches, since the barrel now functions to prevent endwise movement of the pin. This mounting is an important feature of the invention, since alignment of the switch lever 24 is therefore not dependent on alignment of the barrel with the casing 22. Also, since as will be hereinafter disclosed, the whole toggle mechanism of the switch is dependent on proper alignment of the switch lever, there is provided by this improved type of support a much more rigid and workable structure than was heretofore possible, as well as a structure which may be manufactured more economically.

For the purpose of fastening the plate 22 to the casing 20, said plate is provided with oppositely disposed apertures 35 in its rim which align with apertures 35a in the casing, both sets of apertures accommodating pins or rivets 36, see Fig. 3, which are headed over on the plate. Each of the apertures 35a. in the casing is countersunk at its bottom to receive the head of a pin 36, as shown.

Therefore it will be seen that the switch lever 24 is securely mounted relatively to the casing 20, and therefore there is provided as well a firm mounting for the toggle mechanism of the switch.

The barrel 23, Fig. 9, is provided with oppositely disposed cuts or slots 31 at its rear or bottom, and also with a smooth skirt 3B, and said barrel is so proportioned that the skirt 38 may be inserted, with a close fit, within the circular edges of the apertures 3| of the cover plate, so that the lugs 32 of said plate extend into the barrel through the slots or cuts 31 thereof. The lugs 32 serve to'position the barrel 23 on the cover 22 against turning relatively thereto, and said barrel is firmly attached to the' cover plate by flaring over the skirt portion 38 of the, barrelagainst the underside of the raised central portion of said plate, as at 39, Fig. 4.

The barrel 23 is formed to guide the switch lever 24 so that it may be fabricated from a light stock, and said barrel is provided at its front with an apertured end closure 40 and a diametrically disposed slot 4| therein through which extends the lever 24. The slot 3| in the barrel guides the lever 24, preventing sidewise movement or wobble, and therefore said lever need not have a large bearing surface on the pin 34. The slot 4| of the barrel is positioned at right angles to the cuts 31 thereof, so that said slot will be properly, placed relatively to the lever 24 to allow for actuating movement of said lever about the pin 34.

An important feature of the invention is that the barrel 23 now serves to prevent endwise movement of the pin 34 in the lugs 32, and therefore proper positioning of said pin is assured at all times without further anchorage. It will be noted that since the pin 34 does not now pass through the barrel 23 there is obviated the additional machining operations on the barrel which operations were heretofore necessary.

The switch actuating lever 24, see Figs. 3 and 4, is stamped out of flat metallic stock, having a central aperture to receive the pin 34, and having an arm or toggle bar pointed at 43, and said lever has attached to its outermost part a spherical metallic knob 25.

The toggle and contact mechanism of the switch includes two link arms 44, see Figs. 3 and 4, apertured at so as to' be pivotally carried by the pin 34, and having their lower extremities apertured at 46 to carry a metallic spindle 41 on which are disposed contact shoes 48 and insulating washers 49. The contact shoes 46 are preferably in the form of metal rings which are pressed on the ends of the spindle 41 so as to be tightly secured thereto. By this construction the spindle 41 and shoes 48 carried thereby may swing freely within the recess of the casing 22, being pivoted on the pin 34 carried by the cover 22. When the spindle and shoes are in the position shown in Fig. 3 the switch is in open-circuit position, and when the spindle and shoes are urged toward the other or left-hand end of the casing the 'switch is in closed-circuit position.

By the present invention there is provided an improved stationary contact assembly which is engaged by the shoes 48, and which includes improved contact members 50 carried by the casing 22. One such contact member is shown in Fig. 6, the other contact being similar but the exact reverse of that shown. The contact 50 includes a bar 5| extending at its lower extremity in an edgewise direction to form a foot 52, said bar having intermediate its ends a lug 53 integral therewith and extending at right angles thereto and said lug being apertured at 54 to receive a wire-binding screw 55.

The stationary contacts 50 are carried by the casing 22 in specially shaped vertical slots 56, see Fig. 5, disposed in two corners of the casing. One edge of each slot 56 has a longitudinal groove 56a disposed therein while the other edge is rounded off at 56b to form substantially a longitudinal rib. When a contact member 50 is in- 7 the metallic cover plate 22 and being short-cir"-- vides for an exceptionally firm and immovable positioning of the contact in said casing. When the switch is assembled, the stationary contacts 50 are firmly held in the casing slots and against removal therefrom by the insulating shield M, which also prevents said contacts from touching cuited thereby.

open-circuit. position shown, each of these shoes t8 engages the inner curved portion of a bar i thereby electrically connecting the two bars together and closing the circuit of the switch. Preferably either the upper or lower apertures of the link arms M are made slightly oversize so that the shoes M can ride up on the feet 52 when theswitch' is closed.

It can be readily seen that the stationary contacts 50 can be manufactured in large quantitles and with extreme economy, said contacts each being stamped in one piece from sheet metal. The assembly including the slots 56 in the casing'and the contacts 501s extremely simple and permits said casing to be made compact-and so as to have small dimensions, thereby resulting in further economy in manufacture.

For the purpose of urging the contact shoes M toward either open or closed-circuit position there is provided a toggle and spring mechanism which includes a pair of spring-carrying arms 58, preferably formed of insulating material, and pivotally carried on the spindle 47. The arms 58 have reduced shank portions on which is disposed a helical compression spring 59 engagingat one and shoulders 600i said arms and at the other end a slidable plate 6i carried on the arms. The plate 61, see Fig. 11, is rectangular in shape, having two parallel slots therein extending in a longitudinal direction thereof, said slots accommodating the reduced portions 'of the spring arms 58, and said plate has a central portion 62 intermediate the slots which has a depression at 63 for engagement with the pointed bar it of the switch-actuating lever.

Referring to Fig. 3, when the switch lever 2t is moved'to the left the spring 59 will be com- The arrangement of the contact bridging mem-- bers of the switch, including the improved stationary contacts 50 which are held in the slots 56 of the casing, has proved to be extremely satisfatcory and efllcient. The stationary contacts are securely held against movement at all times, and throwing of the switch lever 24 results in a bridging wedge-action between the shoes 48 and 'the feet 52 of the bars 5i, thereby serving to positively eflect a low resistanceelectrical connection between said bars, and a connection which is capable ofhandling relatively high currents.' In addition, when the switch is thrown to open-circuit position the actual breaking ofthe circuit will occur near the tip or toe part of the shoes 52, and should any arcing occur at these points which might ultimately cause dirt to be 75, deposited thereat, such dirt would not impair the desirable low resistance circuit of the switch since the final circuit-closing position of the shoes 48 is past the circuit-breaking oints, and is substantially-against the body porlon of the bar 5i. Also, the movement of the shoes M past the circuit-breaking points of the stationary contacts will tend to remove any dirt which might be deposited at these points as a result of arcing.

The arms M and 58 are preferably made of insulating material so that the contact shoes 48 are electrically insulated from the metal actuating lever 2 and knob 25 of the switch, thereby preventing any possibility of inadvertent electrical shock to a person throwing the switch.

A modified form of toggle mechanism is shown in Figs. 12 and 13. A switch actuating lever Ma is pivotally mounted on a pin 34a passing through an aperture 42a of-thelever, said lever carrying at its outer or upper extremity a spherical knob a, and the lower extremity of the lever having apoint or knee 33a. The pin 34a carries link arms 6E, through the lower ends of which pass a metal spindle 65 having contact shoes 66 thereon. Be-

tween the shoes 6b the spindle 65 is engaged by a U-shaped spring-carrying member 61, the neck' member do not require additional means to hold I them in position relatively to each other. Accordingly, in this embodiment, there is provided a plate 69 which fits between the arms of the member 61, said plate engaging at its upper surface the point 430. of the actuating lever 24a, and engaging at its lower surface theend of the spring 68. The plate 69 has the shape of a'fiattened letter M, see Fig. 12, so that the spring 68 and point 43a are normally centrally positioned thereby. Itis therefore seen that the plate 69 need not be provided with slots, and thus there has been eliminated a machining operation on the plate which was heretofore necessary.

The upper extremities of the arms of the member El preferably are provided with ears Hi to limit movement of the spring 68 when the toggle joint is broken in either direction.

The shoes 66 are firmly attached to the spindle 65 thereby effectively positioning the springcarrying member Blthereon, and the arms of said member are prevented from spreading by the spring 68, which is positioned at its upper end by the plate 69. 1

Variations and modifications may be made within the scope of this invention and portions of the improvements may be used without others.

I claim:

1. In an electric switch, a box-like insulating casing having a bottom, side walls and end walls, and having a vertical slot in a corner formed by a side wall and an end wall, said slot separating said walls and having in one of its edges a longitudinal groove and on the other of its edges a longitudinal rib disposed opposite the groove; and a. contact member fitting into said slot and having a pair of biplanar portions engaging the edges of the slot and respectively interfitting with the groove and rib of said edges so that said member is held thereby in the slot against all but longitudinal movement. 7

v 2. In an electric switch, a box-like insulating casing having a bottom, side walls and end walls,

and having a pair of vertical slots, one at each of the corners formed by the two, side walls and one of the end-walls, each 01 said slots separating the end wall from one oi-the side walls, and

' having in one of its edges a longitudinal groove and in the other of its edges a longitudinal rib disposed opposite the groove; and a pair of contact members fitting one into each of said slots, each of said members having a pair of biplanar portions engaging the edges of its supporting slot and respectively interfltting with thegroove and rib of said edges so that said members are held thereby in the slots against all but longitudinal movement.

3. In an electric switch, a box-like insulating casing having a bottom, side walls and end walls, and having a vertical slot in a corner formed by a side wall and an end wall, said slot separating said walls and having in one of its edges a longitudinal groove; and a contact member fitting into said slot and having a pair of biplanar por tions respectively engaging the edges of the slot, one of said portions interfitting with the groove in the one of said edges so that said member is held thereby in the slot against all but longitudinal movement.

4. The invention as defined in claim 3, in which a planar portion of the contact member extends outward beyond the walls of the casing to form a connection lug, and in which said lug carries means for connecting a wire thereto.

5. The invention as defined in claim 3, in which the bottom of the casing has a groove therein extending in the plane of the inner planar portion of the contact member, and in which said inner portion of the contact member extends downwardly into said groovein the. casing to further securely position the member against movement in the casing.

6. The invention as defined in claim 3, in which the bottom of the casing has a groove therein extending in the plane of the inner planar portion or the contact member'and in which said inner planar portion of the contact member at its bottomextremity extends edgewisely thereof in the groove of the casing to further securely position the member against movement in the casing,

7. The invention as defined in claim 3, in which the bottom of the casing has a groove .therein extending in the plane or the inner planar 8. In an electric toggle switch, a box-like insulating casing having a bottom, side walls and end walls, and having a pair oi. vertical slots, one

at each or the corners formed by the two side walls and one of the end walls, each or said slots separating the end wall from one of the side walls, and having in one of its edges a longitudinal groove; a pair of contact members fitting one into each or said slots, each. of said members having a pair or biplanar portions respectively engaging the edges of its supporting slot, and one or said pair interfitting with the groove of said edge; a contact bridging member adapted to bridge the pair of contacts to electrlcally connect these together; and spring-urged bers; a U-shapedtoggle bar, the base of which 0 -engages the said spindle, the arms of the U-bar being disposed one on each side of the pointed arm of the actuating lever; a spring carried by the arms of the U-bar; and a solid plate disposed between the arms of the U-bar and engaging both the pointed arm of the actuating lever and the end of the said spring to transmit force from the spring to the lever arm.

10. The invention as defined in claim- 9, in which the plate is shaped so that its one side positions the spring centrally thereof, and the other side positions the pointed arm centrally thereof.

11.,The invention as defined in claim 9, in which the plate is in the shape of a flattened letter M so that its one side positions the spring centrally thereof and the'other side positions the pointed arm centrally thereof.

12. In an electric switch, an actuating structure including a switch cover plate having a pair of apertured lugs extending outwardly of the plate; a pin carried by the lugs of the plate in the apertures thereof; an actuating lever pivotally carried by the pin; and a shell carried by the plate for mounting the latter on a supporting plate, the inner walls of the shell engaging the ends of the pin to restrain endwise movement of the latter, and said shell having a pair of slots through which the lugs extend, to prevent turning of the shell relatively to the plate.

13. In an electric switch, an actuating structure including a switch cover plate having an aperture therein, and having a pair of apertured lugs extending outwardly of the plate,- said lugs being disposed on opposite edges of the aperture; a pin carried by the lugs or the plate in the apertures thereof; an actuating lever pivotally carried by the pin and passing through the aperture in the plate; and means carried in the aperture of the plate for mounting the latter on a supporting plate, including means for pre venting endwise movement of the pin in the lugs.

14. The invention as defined in claim 13, in which themeans carried in the aperture of the plate includes a threaded barrel having a shoulder and a flared-over end engaging the edges of the aperture of the plate, said barrel enclosing the lugs 01 said plate.

15. The invention as defined in claim 13, in which the means carried in the aperture'of the plate includes a threaded barrel having a shoul-- der and a flared-over end engaging the edges of the aperture of the plate, said barrel enclosing the lugs of said plate, and in which the portion of the plate around the aperture therein is raised to form an internal flange which is held between the shoulder and flared-over end of the barrel.

16. In an electric toggle switch, the combina-' tion of a box-like insulating casing having a bottom, side walls and end walls, and having a of vertical slots, one at each of the corn ormed bythe two side walls and one e end walls each or said slots sep ng a side wall irom the end wall; a or contact members fitting one into each of said slots, each or said members having a contact bar disposed within the casing and 1 a connection lug extending through the slot and out of the casing; a cover plate fastened to the insulating casing, said plate having an aperture'therein and having a pair of apertured lugs extending outwardly of the plate, said lugs being disposed on opposite sides of the aperture; a pin carried by the lugs in the apertures thereof; an actuating lever pivotally carried by the pin and passing through the aperture in the plate; a contact bridging member adapted to electrically connect the contact bars within the casing; a pair of link members pivotally carried by the pin, said members carrying at their other extremities the contact bridging member; a

spring-urged toggle joint between the contact bridging member and the switch lever whereby movement of the lever in one direction will cause the contact bridgingmember to snap to a position of rest engaging the contacts of the casing to electrically connect these, and'movement of the lever in the other direction will cause the contact bridging member to snap to a position of rest away from the contacts or the casing so as to open-circuit said contacts; and means carried in the apertureof the plate for mounting the switch on a supporting plate, including means for preventing endwise movement of the pin in the lugs of the plate.

r ARTHUR C. GAYNOR. 

